Turbine component tracking system

ABSTRACT

A turbine component tracking system is provided. The turbine component tracking system is advantageously adapted to determine the remaining life of individual turbine components based on how and where they are used as well as if and how they are repaired. The turbine system is also advantageously adapted to track and analyze design, manufacturing and repair changes or modifications performed on turbine components.

FIELD OF THE INVENTION

This invention relates generally to the field of component trackingsystems and in particular, to a turbine component tracking systemadapted to determine the remaining life of individual turbine componentsbased on how and where they are used as well as if and how they arerepaired, and also in particular to a turbine component tracking systemadapted to track and analyze design, manufacturing and repair changes ormodifications performed on turbine components.

BACKGROUND OF THE INVENTION

Gas turbine engines are known to include a compressor section forsupplying a flow of compressed combustion air, a combustor section forburning fuel in the compressed combustion air, and a turbine section forextracting thermal energy from the combustion air and converting thatenergy into mechanical energy in the form of a rotating shaft.

Modern high efficiency combustion turbines have firing temperatures thatexceed about 2,700° F., and even higher firing temperatures are expectedas the demand for more efficient engines continues. Many components thatform the “hot gas path” combustor and turbine sections are directlyexposed to aggressive hot combustion gasses, for example, the combustorliner, the transition duct between the combustor and turbine sections,and the turbine stationary vanes and rotating blades and surroundingring segments. In addition to thermal stresses, these and othercomponents are also exposed to mechanical stresses and loads thatfurther wear on the components. Other turbine components, such aselectronic and mechanical controllers, fuel metering equipment,auxiliaries, load packages including generators and exciters, and valvessimilarly receive in-service wear.

It is known to perform detailed periodic scheduled maintenance ofturbine components based upon benchmark manufacturer recommendationsdeveloped from engineered design parameters in view of anticipatedturbine operation conditions. However, a shortcoming of this methodologyis that actual turbine operating conditions often appreciably differfrom the anticipated turbine operating conditions due to intentional(e.g. running the turbine at higher combustion temperatures) orunintentional (e.g. non-optimal shutdowns, trips, fast cool downs, waterwashing, and fuel nozzle water purges) reasons. Thus, the componentscommonly experience temperatures, cycles, loads, stresses, strains, etc.that are greater or less than for which they were designed. Accordingly,Type I and II errors occur in connection with the periodic scheduledmaintenance, that is, maintenance is performed when the turbinecomponents are fine (Type I) and maintenance is not performed when theturbine components need to be repaired, refurbished or replaced (TypeII).

Several approaches have been taken to address this shortcoming. Oneapproach involves developing less expensive and time consuminginspection and maintenance procedures, such as non-destructive andin-operation examination of the turbine components, for example thosedescribed in U.S. Pat. Nos. 4,746,858 and 5,140,528. Another approachinvolves creating individualized maintenance schedules uniquelyassociated with and based on the actual operating history of aparticular turbine, for example that described in U.S. Pat. No.6,343,251.

If a unique individual turbine maintenance schedule is created, aproblem arises if an individual turbine component is used on more thanone turbine. Another problem arises if a component type (e.g. row 1blade) is not identical with another similar component type (e.g. row 1blade), for example, if one row 1 blade was manufactured with one typeof ceramic thermal barrier coating and another row 1 blade wasmanufactured with another type of ceramic thermal barrier coating, thisdifference is not addressed. Another problem arises if some individualcomponent types are repaired or replaced while other individualcomponent types are not repaired or replaced within the turbine.Oftentimes, some components are replaced that still have serviceablelife in them to “reset” the clock on the repair cycle.

Accordingly, there is a need for additional approaches to reducemaintenance costs and improve upon the prior art.

SUMMARY OF THE INVENTION

A turbine component tracking system is provided. The turbine componenttracking system is advantageously adapted to determine the remaininglife of individual turbine components based on how and where they areused as well as if and how they are repaired. The turbine system is alsoadvantageously adapted to track and analyze design, manufacturing andrepair changes or modifications performed on turbine components.

One aspect of the present invention involves a turbine componenttracking system, comprising: a plurality of marked turbine components;at least one turbine control system adapted to obtain operational datafor the turbine components; and a central processing station operativelyconnected to the at least one turbine control system and adapted toupload the operational data from the at least one turbine controlsystem, whereby desired turbine component specific information isdetermined and output by the central processing station for turbinecomponent tracking purposes.

Another aspect of the present invention involves a method of trackingturbine components, comprising: marking a plurality of turbinecomponents; placing the turbine components in a plurality of turbines;operating the turbines; obtaining operational data from the turbines viaat least one turbine control system; uploading the operation data fromthe turbine control systems to a central processing station; and usingthe uploaded data at the central processing station to track desiredaspects of the turbine components.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other advantages of the invention will be more apparent fromthe following description in view of the drawings that include:

FIG. 1 is a flowchart of an exemplary turbine component tracking systemof the present invention;

FIG. 2 is a schematic diagram of an exemplary architecture for thecentral turbine component tracking system;

FIG. 3 is an exemplary database listing of information for a trackedturbine component; and

FIG. 4 is an exemplary database listing of information for a pluralityof tracked turbine components.

DETAILED DESCRIPTION OF THE INVENTION

The invention described herein employs several basic concepts. Forexample, one concept relates to a system for tracking turbine componentsfrom when the component is manufactured, through its use in a turbine,to any repair or refurbishment performed on the component, and to anysubsequent use in the same or different turbine. Another concept relatesto a method of tracking turbine components to help coordinate or matchnew and used turbine components with turbines having needs for aparticular new or used turbine component. Another concept relates to asystem that allows changes or modifications to a turbine component,whether during the design, manufacturing or repair process, and whetherintentional or unintentional, to be tracked and analyze; thus dynamicchanges to a turbine component throughout its life can be tracked.

The present invention is disclosed in context of use as a trackingsystem for a turbine component 2 to be used within a combustion turbineengine. The principles of the present invention, however, are notlimited to turbine components 2 to be used within a combustion turbineengine or even to turbine components 2. For example, the principles ofthe present invention can be used to track other components that can beused in more than one place and/or can be repaired or refurbished one ormore times, such as power plant boilers, coal grinding ball mills,boiler fans, industrial engines or any other high maintenance or highwear item that is systematically repaired, replaced or refurbished. Oneskilled in the art may find additional applications for the apparatus,processes, systems, components, configurations, methods, andapplications disclosed herein. Thus, the illustration and description ofthe present invention in context of an exemplary turbine component 2tracking system is merely one possible application of the presentinvention.

Referring now to FIG. 1, an exemplary flowchart of a turbine componenttracking system is provided.

Step 1, illustrated as reference number 10, depicts turbine componentsmarked or coded with identifying indicia. This can be performed at anytime during or after the manufacture of the component. The indicia maybe any suitable identifier, such as a serial number, bar code,combinations thereof and the like. For example, commonly assigned U.S.patent application Publication Nos. US-2003-0094493 andUS-2003-0097315-A1, each of which are incorporated by reference hereinin their entirety, disclose applying a bumpy bar code to a portion of acomponent during the manufacturing process. For another example, theindicia may be a plurality of serial numbers separately applied to theturbine component for separate reasons, such as a first serial number toidentify the metallic base material applied by one manufacturingfacility and a second serial number to identify the ceramic coatingmaterial applied by another manufacturing facility and anothermanufacturing facility. For another example, the indicia could identifyscrap.

Step 2, illustrated as reference number 12, depicts the marked turbinecomponents data inputted into a central processing station, such as acomputer client-server system. This input could be performed by manualdata entry techniques or by automated techniques such as bar codereaders operatively connected to the client-server system.

Step 3, illustrated as reference number 14, depicts the turbinecomponents placed in operational service in one or more turbines.Typically the components may be placed in service throughout a fleet ofdozens or hundreds if not thousands of turbines. The turbine componentsmay include hot gas path components or other components as explainedabove or understood by those skilled in the art.

Step 4, illustrated as reference number 16, depicts the turbine controlsystems for the turbines within which turbine components are locatedobtaining operating data regarding the environment in which the turbinecomponents operate. The turbine control system may be presently known,such as Siemens Westinghouse's TXP™ turbine control system, or laterdeveloped. Of course, data collection techniques other than the turbinecontrol system could be used to obtain the turbine operating data, suchas manual charts and graphs. This operational data may includeequivalent base hours (EBH), equivalent starts (ES), maximum and averagecombustion and blade row temperatures and pressures, fuel type, numberof starts, number of aborted starts, runbacks, fast stops, trips, loadchanges, fast cool down cycles, water washing, fuel nozzle purging, wetcompression operating parameters, inlet fogging operating parameters,combinations thereof and the like. As is understood by those skilled inthe art, other suitable operational data can also be obtained, such asthat described in U.S. Pat. No. 6,343,251.

Step 5, illustrated as reference number 18, depicts downloading theoperating data from the turbine control systems and uploading it to thecentral processing station. This downloading and uploading isadvantageously performed by computerized techniques such asinternet-based data transfers or point-to-point modem or cablecommunications systems, and are advantageously automated such that thedownload and upload is performed without active human involvement,although there is not requirement for the technique to be automated orcomputerized. For example, the downloads could be performed by manualdata entry techniques. FIG. 2 illustrates an exemplary turbine trackingsystem architecture that is electronically interconnected to a pluralityof turbine control systems and adapted to download operational data fromthe turbine control systems and upload such data to the centralprocessing station 22. The operational data may be provided directlyfrom the turbine control systems 24 or through an intermediary powerplant 26 or power producer 28 site or other intermediary. Theoperational data need not be fully integrated into the centralprocessing station, for example, operation data from one or more powerplants or power producers could remain with and be used by that powerplant or power producer without being uploaded to or integrated with thecentral processing station. Still referring to FIG. 2, other facilitiesmay be integrated into the central processing station 22, such as acomponent repair facility 30, a component manufacturing facility 32, ora component storage warehouse 34; alternatively, one or more of thefacilities could remain independent of the central processing facilityand only be integrated with one or more power plants or power producers.

Step 6, illustrated as reference number 20, depicts the centralprocessing station using the uploaded operational data to track theturbine components and advantageously determine or calculate remaininglife of the turbine components or other component-specific information.If remaining life is tracked, it can be determined in a variety of waysbased on the operational data as will be understood by those skilled inthe art, such as that described in U.S. Pat. No. 6,343,251. Otheroperational-based and non-operational-based data, such as consumed life,repair operations, turbines in which used, also may be determined aswill be understood by those skilled in the art. FIGS. 3 and 4 showexemplary data lists that can be generated by the central processingstation displaying certain turbine component data including serialnumbers, part description, remaining life, consumed life, repairoperations, power plants used in, turbines used in, location withinturbine, component design modifications, and component manufacturingmodifications.

By the above-described configuration, individual turbine components andoperational data associated with the individual turbine components canbe tracked from when the components are manufactured, through their usein a turbine, to any repair or refurbishment performed on eachcomponent, and to any subsequent use in the same or different turbine.Failed components could be positively noted to prevent their inadvertentuse. Additionally, the tracking system allows for new or repairedturbine components to be coordinated or matched with turbines havingparticular turbine component needs. Further, the tracking system allowsfor changes or modifications to a turbine component to be tracked andanalyzed, whether such changes or modifications occur during the designprocess (e.g. new ceramic thermal barrier coating composition, duringthe manufacturing process (e.g. higher temperature superalloy heattreatment) or during repair (e.g. experimental metal powder fillermaterial applied to sensitive repair site) and the like. Also, thetracking system allows for detailed identification of subcomponents,compositions and other features of the individual components, such asthe particular superalloy material composition a blade was made of orthe assembly route and conditions that a combustor liner experienced.Further, the tracking system allows for statistical analysis of theturbine components based on the data at the central processing station.

The above-described steps need not be performed in the sequenceillustrated in above and in FIG. 1. Also, all steps need not beperformed and additional steps may be performed between, before or afterthe above-described steps.

While the preferred embodiments of the present invention have been shownand described herein, it will be obvious that such embodiments areprovided by way of example only. Numerous variations, changes andsubstitutions will occur to those of skill in the art without departingfrom the invention herein. Also, one or more aspects or features of oneor more embodiments or examples of the present invention may be used orcombined with one or more other embodiments or examples of the presentinvention. Accordingly, it is intended that the invention be limitedonly by the spirit and scope of the appended claims.

1. A method of tracking turbine components, comprising: marking aplurality of turbine components with indicia applied to a surface of thecomponents; placing the marked turbine components in a plurality ofturbines; operating the turbines; obtaining operation data from theturbines via at least one turbine control system; uploading theoperation data from the turbine control systems to a central processingstation; and using the uploaded data at the central processing stationto track desired aspects of the marked turbine components, wherein themarking identifies a material composition from which at least a portionof the turbine component was manufactured.
 2. A method of trackingturbine components, comprising: marking a plurality of turbinecomponents with indicia applied to a surface of the components; placingthe marked turbine components in a plurality of turbines; operating theturbines; obtaining operation data from the turbines via at least oneturbine control system; uploading the operation data from the turbinecontrol systems to a central processing station; and using the uploadeddata at the central processing station to track desired aspects of themarked turbine components, wherein the marking identifies amanufacturing step from which at least a portion of the turbinecomponent was manufactured.